Carpeting installation with removable access panel

ABSTRACT

A method of carpeting a floor which includes an area requiring access through the carpeting, comprising the steps of: securing to the floor an upwardly facing, endless channel which surrounds the desired area; laying the carpeting over the channel; cutting the carpeting along the channel both externally and internally thereof to expose the channel and to provide within the channel a removable carpeting panel; and pressing into the channel the leg of an endless, flexible T-shaped removable strip having internal and external flanges respectively overlying the carpeting internally and externally of the channel and adapted to hold the removable carpeting panel in place. A method of forming and/or packaging an endless, flexible Tshaped strip of thermoplastic material, including the steps of: forming the endless strip by bonding together spaced ends of a starting strip having a length equal to the perimeter of the endless strip; providing an inner card and an outer card adapted to surround the inner card in the same plane with an endless gap therebetween; positioning the inner card within the outer card in the same plane and with the endless gap therebetween; heating the endless strip to render it pliable; and pressing the leg of the endless strip into the endless gap between the inner and outer cards with the flanges of the endless strip respectively overlying the inner and outer cards. The two cards serve to maintain the desired configuration for the endless strip and also serve as a package therefor.

United States Patent [1 1 Hill [ 1 May6,1975

[ CARPETING INSTALLATION WITH REMOVABLE ACCESS PANEL [75] Inventor: Harvey J. Hill, Los Angeles, Calif.

[73] Assignee: Roberts Consolidated Industries,

Inc., City of Industry, Calif.

22 Filed: May 21,1973

21 App]. No.: 362,389

Related U.S. Application Data [62] Division of Ser. No. 162,548, July 14, 1971.

[52] U.S. Cl. 206/303; 206/321; 206/486 [51] Int. Cl B65d 85/02 [58] Field of Search 206/303, 321, 320, 407,

206/486, 490, 493; 52/400; 220/DIG. 3, 46 R [56] References Cited UNITED STATES PATENTS 2,189,138 2/1940 Eichner 220/DIG. 3 2,288,329 6/1942 Smith 52/400 2,367,409 l/1945 Kuhler 220/46 R 2,620,062 12/ l 952 Schuler 206/320 2,809,728 10/1957 Olson 52/400 3,009,216 11/1961 Kimber 52/400 3,113,670 l2/l963 Whitting 206/407 3,221,456 12/1965 Capel 52/400 3,628,688 12/1971 Haggard et al 220/46 R Primary Examiner-William T. Dixson, Jr. Attorney, Agent, or FirmHarris, Kern, Wallen & Tinsley [57] ABSTRACT A method of carpeting a floor which includes an area requiring access through the carpeting, comprising the steps of: securing to the floor an upwardly facing, endless channel which surrounds the desired area; laying the carpeting over the channel; cutting the carpeting along the channel both externally and internally thereof to expose the channel and to provide within the channel a removable carpeting panel; and pressing into the channel the leg of an endless, flexible T- shaped removable strip having internal and external flanges respectively overlying the carpeting internally and externally of the channel and adapted to hold the removable carpeting panel in place.

A method of forming and/or packaging an endless, flexible T-shaped strip of thermoplastic material, including the steps of: forming the endless strip by bonding together spaced ends of a starting strip having a length equal to the perimeter of the endless strip; providing an inner card and an outer card adapted to surround the inner card in the same plane with an endless gap therebetween; positioning the inner card within the outer card in the same plane and with the endless gap therebetween; heating the endless strip to render it pliable; and pressing the leg of the endless strip into the endless gap between the inner and outer cards with the flanges of the endless strip respectively overlying the inner and outer cards. The two cards serve to maintain the desired configuration for the endless strip and also serve as a package therefor.

3 Claims, 13 Drawing Figures PATENTEU MAY 6 [s75 SHEEI 10F 2 All n.

CARPETING INSTALLATION WITH REMOVABLE ACCESS PANEL This is a division of application Ser. No. 162,548, filed July 14, 1971.

BACKGROUND OF INVENTION The present invention relates in general to carpeting a floor which includes an area requiring access through the carpeting. For example, the floor area in question may comprise a removable panel for access to components of underfloor conduit systems, or the like. In such a carpeting installation, it is necessary to provide a removable carpeting panel over the floor area requiring access, and to provide means for securing and covering the edges of the carpeting panel and the carpeting surrounding it.

In the past, the provision of means for releasably securing the removable carpeting panel and for securing the carpeting around it has necessitated tedious and costly hand cutting and fitting of mitered metal moldings around the desired area. Also, in accordance with some past procedures, the raw edge of the carpeting surrounding the desired area is turned under for protective purposes. When this is done, the section of carpeting which has been cut out is too small to cover the opening, which means that a removable panel must be provided from another portion of the roll of carpeting, with attendant color and/or pattern matching problems.

SUMMARY AND OBJECTS OF INVENTION With the foregoing background in mind, primary ob jects of the present invention are to provide a carpet securing means around the desired floor area which permits utilizing as the removable carpeting panel the section of carpeting cut out of the main carpeting, thereby avoiding color and/or pattern matching problems, and which is preformed to avoid time consuming and expensive hand cutting and fitting of conventional mitered moldings. Another and related primary object is to provide a carpet securing means around the desired floor area which is capable of being installed quickly and easily by relatively unskilled labor.

Considering the invention more specifically now, an important object thereof is to provide a carpeting installation and method which involve: securing to the floor around the area to which access is required an upwardly facing, substantially endless channel; laying the carpeting over this channel; cutting the carpeting along the channel both externally and internally thereof, the internal cut defining a removable carpet panel for covering the desired floor area; and pressing into the channel the leg of an endless, flexible T-shaped strip having external and internal flanges respectively overlying the carpeting externally and internally of the channel. This strip covers the cut edge of the main carpeting externally of the channel, and also covers the cut edge of the removable carpet panel within the channel. Additionally, the T-shaped strip serves to retain the removable carpet panel within the channel.

The foregoing installation, since it utilizes preformed parts, may be made quickly and easily with relatively unskilled labor, which is an important feature. Another feature is that the same basic principles may be applied to carpeting which is cemented to the floor, or carpeting which is laid in tension over separate padding.

Still another important object of the invention is to provide a unique procedure for forming and/or packaging the endless T-shaped strip.

More particularly, an object of the invention is to make the endless T-shaped strip from a starting strip having spaced ends by bonding the ends of the starting strip together, and then forming the resulting endless strip into the desired final configuration for insertion of the central leg thereof into the upwardly facing channel mentioned. A related object is to utilize a thermoplastic material, such as polyvinyl chloride, which can be formed readily upon heating.

Still more particularly, a key object of the invention is to form and/or package the heated, endless T-shaped strip of thermoplastic material by: providing an inner card and an outer card adapted to surround the inner card in the same plane with an endless gap therebetween; positioning the inner card within the outer card in the same plane with the endless gap between the two cards; and then pressing the leg of the T-shaped strip into the endless gap with the flanges of the strip respectively overlying the two cards. The latter may be made of any suitable inexpensive material, such as cardboard.

With the foregoing procedure, the two cards hold the endless T-shaped strip in the desired configuration until it sets, thereby serving as a form. The two cards continue to perform this function until the T-shaped strip is to be used, thereby preventing any residual memory that the thermoplastic material may have from tending to return it to its configuration prior to forming. Further, the two cards between which the leg of the T- shaped strip is inserted serve as a package for the strip during shipment, storage, and the like, which is another important feature.

The foregoing objects, advantages, features and results of the present invention, together with various other objects, advantages, features and results which will be evident to those skilled in the art to which the invention relates in the light of this disclosure, may be achieved with the exemplary embodiments illustrated in the accompanying drawings and described in detail hereinafter.

DESCRIPTION OF DRAWINGS In the drawings:

FIG. 1 is a perspective view of a completed carpeting installation provided with a removable access panel in accordance with the invention;

FIG. 2 is an enlarged plan view of an upwardly facing channel forming part of the invention;

FIG. 3 is a further enlarged fragmentary plan view duplicating a portion of FIG. 2;

FIG. 4 is an enlarged sectional view taken as indicated by the arrowed line 4-4 of FIG. 2;

FIG. 5 is an enlarged, fragmentary sectional view taken as indicated by the arrowed line 55 of FIG. 1;

FIG. 6 is an enlarged, fragmentary plan view showing a portion of an endless, flexible T-shaped strip constituting a part of the invention;

FIG. 7 is an enlarged sectional view taken as indicated by the arrowed line 7-7 of FIG. 6;

FIG. 8 is a view similar to FIG. 5, but showing another embodiment of the invention;

FIG. 9 is an isometric view of an endless, flexible T- shaped strip of the invention prior to forming it into its final configuration;

FIG. is an exploded isometric view of means for forming the endless strip of FIG. 9 into its final configuration and for packaging it in that configuration;

FIG. 11 is a perspective view illustrating the forming and packaging means of FIG. 10 in use to form and package the endless T-shaped strip;

FIG. 12 is a fragmentary sectional view taken as indicated by the arrowed line l2-l2 of FIG. 11; and

FIG. 13 is an isometric view of the T-shaped strip packaged in its final configuration in accordance with the invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS OF INVENTION Referring initially to FIGS. 1 and 5 of the drawings, illustrated therein is a carpeting installation 20 on a floor 22 having an area 24 to which access is necessary. For example, as shown in FIG. 5, the floor area 24 may include a removable panel 26 providing access to some underfloor installation. The carpeting installation 20 includes a carpet 28 having a removable portion or panel 30 which overlies the floor area 24 to provide access to the removable floor panel 26. In the particular carpet installation 20 illustrated, the carpet 28 is bonded to the floor 22 and the removable carpet panel 30 is seated directly on the floor area 24.

The present invention comprises preformed means 32 for covering the edges of the removable carpet panel 30 and the opening in the carpet 28, and for securing the removable carpet panel.

The preformed covering and securing means 32 includes as one of its components and endless and substantially continuous, upwardly facing channel 34 secured to the floor 22 around the floor area 24 requiring access. Although the channel 34 is shown as substantially square, it may have any desired configuration.

In the particular embodiment illustrated, the channel 34 is provided with an outwardly extending, discontinuous flange 36 adhered to the floor 22, the edge of the carpet 28 surrounding the channel 34 being adhered to the upper surface of the flange 36. In this embodiment, the channel 34 was formed by bending a straight extrusion into the desired endless configuration, after making a number of transverse cuts in the extrusion in the areas thereof corresponding to the corners of the finished endless channel. As best shown in FIG. 3, each cut 38 extends entirely through the flange 36 and extends through the outer wall 40 and the base 42 of the channel to the inner wall 44 thereof. Thus, such cuts permit bending the straight extrusion into the endless configuration shown without changing the width of the channel 34. The abutting ends of the channel 34 need not be welded together.

It will be understood that the channel 34 may be made in other ways without departing from the invention. For example, it may be a molded product of a suit able plastic material, in which case the cuts 38 would not be present, and the channel 34 and its flange 36 would be continuous and endless.

Considering an important feature of the invention, the channel 34 is secured to the floor 22 around the area 24 prior to laying the carpet 28. The carpet is then placed on the floor 22 over the channel 34, which can readily be felt through the carpet. External and internal cuts are then made in the carpet 28 along the outer and inner walls 40 and 44 of the channel 34, using the channel walls themselves as guides. This results in close fits between the outer carpet edge 46 surrounding the channel 34 and the inner carpet edge 48 within the.

channel, this inner carpet edge defining the removable carpet panel 30.

After the foregoing operations have been completed, the carpet edges 46 and 48 are covered, and the removable carpet panel 30 is secured, by pressing into the channel 34 a leg 50 of an endless, flexible, removable T-shaped strip 52 having external and internal flanges 54 and 56 adapted to overlie and conceal the outer and inner carpet edges 46 and 48. (As shown, the leg 50 is a central leg and the flanges 54 and 56 have the same width. However, the leg 50 may be offset with flanges of different widths.) Additionally, the internal flange 56 releasably secures the removable carpet panel 30. To resist withdrawal of the central leg 50 of the T- shaped strip 52 from the channel 34, the inner surfaces of the walls 40 and 44 of the channel may be longitudinally serrated, as best shown in FIG. 4. Additionally, the central leg 50 terminates at its lower end in longitudinally extending, laterally projecting lips 58 which fit into a longitudinal recess 60 at the bottom of the channel, below the longitudinal serrations therein, to further resist withdrawal.

As previously indicated, the removable carpet panel 30 may be retained, particularly if small, solely by the internal flange 56 of the endless T-shaped strip 52. However, if desired, especially with larger removable panels, the panel may also be secured to the floor area 24 with a releasable adhesive, pieces of double-faced pressure sensitive tape, or the like.

The preformed covering and securing means 32 has been described thus far in connection with a carpet 28 which is adhered to the floor 22. As shown in FIG. 8, if the invention is to be used with a carpet 62 laid in tension over a pad 64, the channel 34 may be equipped with a raised external flange 66 adapted to be nailed to the floor 22 and provided with carpet retaining pins 68. In all other respects, the preformed covering and securing means shown in FIG. 8 is identical to that described previously.

As will be apparent from the foregoing, the preformed covering and securing means 32 may be installed quickly and easily without requiring any particular skill, the installation of the channel 34 and the T- shaped strip 52 being simple operations. Further, cutting the carpet 28 to form the necessary opening therein and to form the removable panel 30 is a simple operation since the channel 34 serves as a guide or template. Additionally, since the removable panel 30 is formed by the part of the carpet 28 which is cut out for access to the floor area 24, there are no color and/or pattern matching problems, which is another important feature.

The T-shaped strip 52 may be removed readily to permit removal of the panel 30, or to permit replacement of the strip itself, if desirable or necessary. Also, the carpet panel 30 can be removed or installed by pulling it from under, or by inserting it under, the internal flange 56 without removing the T-shaped strip 52, this being permitted by the flexibility of the strip.

Turning now to another aspect of the invention, an

important feature resides in the procedure for forming the required cross section, and thereby eliminates any necessity for numerous molds of different shapes and- /or sizes.

Initially, a starting strip of the desired T-shaped cross section is cut with a length substantially equal to the perimeter of the desired endless strip 52. The material used is a suitable thermoplastic, such as polyvinyl chloride. The two ends of the starting strip are bonded together in register, as indicated at 72 in FIG. 9, to form a closed loop 74. Preferably, the central leg 50 of the T extends inwardly.

Next, the loop 74 is heated sufficiently to render it soft and pliable. Then the loop 74 is twisted to achieve the desired orientation of the central leg 50 longitudinally of the ultimate endless strip 52, instead of radially as in the closed loop 74. The central leg 50 is then pressed into an endless gap 76 between inner and outer card-like members or cards 78 and 80 disposed in the same plane. These cards are formed of any suitable inexpensive material, such as ordinary cardboard. The cards 78 and 80 are retained in the proper positions by a jig or fixture 82 having pins 84 fitting into corresponding holes in the cards, as will be clear from FIGS. and 11. The jig 82 is provided with a closed groove 86 corresponding to and of substantially the same dimensions as the recess 60 in the channel 34. As soon as the central leg 50 of the heated T-shaped strip 52 has been pressed into the endless gap 76 between the cards 78 and 80, and the flanges 54 and 56 have been seated on these cards, the assembly of the T-shaped strip and the two cards may be removed from the jig 82, as shown in FIG. 13.

The two cards 78 and 80 constitute a form for maintaining the desired configuration of the T-shaped strip 52 as it cools and sets. Further, the cards 78 and 80 continue to act as a form for the T-shaped strip 52 until such time as this strip is to be installed in the channel 34, thereby preventing any residual memory that the thermoplastic material may have from tending to return the T-shaped strip to its original configuration, which is an important feature. Still further, the two cards 78 and 80 constitute a package for the T-shaped strip 52, which is another important feature.

It will be noted that the lips 58 on the central leg 50 of the T-shaped strip 52 pass completely through the endless gap 76 between the inner and outer cards 78 and 80 into the groove 86, which is wide enough to permit the lips 58 to assume their desired positions. With this arrangement, the desired cross sectional configuration for the lipped area of the central leg 50 is preserved, which is another feature. The lips 58 bear against the lower sides of the respective cards 78 and 80 to lock the assembly together.

It will be understood that the forming and packaging procedure illustrated in FIGS. 9 to 13 of the drawings may be utilized for any desired configuration of the T- shaped strip 52, and is not limited to the particular substantially square configuration illustrated.

Although exemplary embodiments of the invention have been disclosed for purposes of illustration, it will be understood that various changes, modifications and substitutions may be incorporated in such embodiments without departing from the spirit of the invention as defined by the claims appearing hereinafter.

I claim as my invention:

1. In a form and/or package, the combination of:

a. an inner card;

b. an outer card in the same plane as and surrounding said inner card with an endless gap therebetween;

c. an endless, flexible T-shaped strip having a leg and inner and outer flanges;

d. said strip having an initial, unrestrained configuration wherein said leg is in a plane extending inwardly of said strip as a whole;

e. said strip having a twisted restrained configuration wherein said leg is substantially perpendicular to the plane of said cards and is disposed in said gap, and wherein said inner and outer flanges respectively overlie said inner and outer cards; and

f. said cards maintaining said strip in said restrained configuration.

2. A form and/or package as set forth in claim 1 wherein the leg of said strip terminates in laterally projecting lips. I

3. A form and/or package according to claim 1 wherein said flanges are of equal width. 

1. In a form and/or package, the combination of: a. an inner card; b. an outer card in the same plane as and surrounding said inner card with an endless gap therebetween; c. an endless, flexible T-shaped strip having a leg and inner and outer flanges; d. said strip having an initial, unrestrained configuration wherein said leg is in a plane extending inwardly of said strip as a whole; e. said strip having a twisted restrained configuration wherein said leg is substantially perpendicular to the plane of said cards and is disposed in said gap, and wherein said inner and outer flanges respectively overlie said inner and outer cards; and f. said cards maintaining said strip in said restrained configuration.
 2. A form and/or package as set forth in claim 1 wherein the leg of said strip terminates in laterally projecting lips.
 3. A form and/or package according to claim 1 wherein said flanges are of equal width. 